Bosch Mahle Turbo Systems—supply contracts for one million turbo-chargers per year, even before market entry

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Stuttgart, September 2011—The trend for the combustion engine is toward downsizing. This reduction in the number of cylinders and displacement while maintaining high torque and engine output is the decisive basis for meeting rising efficiency and emissions requirements. The turbocharger plays a key role in both diesel and gasoline engines.

Market experts anticipate a doubling of the number of turbocharged two- and three-cylinder engines by 2016. Highly efficient four-cylinder engines will grow by 20 percent to reach over 20 million units. While turbochargers have largely become standard in passenger car diesel engines and in light and heavy commercial vehicles, there is substantial pent-up demand in gasoline engines. Even here, the predictions are clear: in the near future, every automobile manufacturer will offer turbocharged gasoline engines, and the demand for turbochargers will more than double.

Bosch Mahle Turbo Systems is very well placed in this dynamic environment. The young company has already concluded supply contracts with six well-known vehicle and engine manufacturers, even before entering the market. This represents a volume of more than one million turbochargers per year. "This customer trust honors our efforts to bring to the market a high-quality product that meets the highest expectations at a competitive price," says Dr. Andreas Prang, managing director of Bosch Mahle Turbo Systems for the areas of production, purchasing, and quality.

The product portfolio includes both turbochargers with wastegates, for gasoline engines ranging from 45 to 220 kW power output, and those with variable turbine geometry (VTG). For diesel engines, the portfolio extends from passenger cars to heavy commercial vehicles, from 30 to 530 kW. This includes particularly compact charger systems, where the exhaust manifold is integrated in the turbine housing. Dr. Martin Knopf, managing director for the areas of development, sales, and finance, describes the focused approach: "A thoroughly process- and quality-oriented development procedure, from the drawing, to the first prototypes, to the series production turbocharger, is the hallmark of our product. This allows us to implement individual customer requests quickly, while guaranteeing a high level of quality."

Whether used in a two-cylinder gasoline engine as an extreme downsizing concept, in an efficient and powerful four-cylinder diesel passenger car, or in a high-displacement diesel commercial vehicle—Bosch Mahle Turbo Systems sets a very high bar for the disciplines of efficiency, service life, and acoustics.

Turbochargers for downsizing engines require perfect dynamic behavior when changing between two different load cases. This demands the lowest possible moment of inertia for the rotor, i.e., the shaft with the impeller and exhaust gas turbine. Bosch Mahle Turbo Systems achieves this by reducing the weight and bearing friction. These are details that positively affect spontaneous responsiveness. This parameter is a fundamental prerequisite for low fuel consumption and good elasticity during operation. However, these characteristic properties are finally determined by the overall design and an optimal flow, which is calculated in advance using refined in-house simulation tools. This results in turbochargers with excellent efficiency produced by Bosch Mahle Turbo Systems.

Thanks to new, high-precision production methods for the rotor and bearing as key components, turbochargers set benchmarks for service life and acoustic behavior. The impellers, which are machined to very tight tolerances from continuously cast aluminum bars, make a significant contribution to this performance. Thanks to high-quality manufacturing methods, the air volume between the compressor blades is particularly consistent, thus preventing disturbing pulsation noise.

The two production plants, Blaichach in Allgäu/Germany, and St. Michael/Austria, have cutting-edge production lines. Preseries production is currently ramping up. Turbochargers for the first large-scale production projects will be manufactured at the start of 2012. More than 200 employees are already working at Bosch Mahle Turbo Systems, growing to over 300 by 2013. "We want to continue to grow, and are still looking for many technicians. Creative minds have excellent opportunities here," comments Dr. Martin Knopf.

Bosch Mahle Turbo Systems, a joint venture of Bosch and MAHLE, with a strong understanding of the complete system for combustion engines and outstanding know-how in development and large lot production of engine parts and components, is currently developing exhaust gas turbocharger systems for engines in passenger cars and light commercial vehicles. The company was founded in June 2008, and currently employs more than 200 people.



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